Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
ARMORED CABLE WITH INTEGRAL SUPPORT
RELATED APPLICATION
[001] This application is being filed on 16 May 2008, as a PCT
International Patent application in the name of Paul H. WHITE, a citizen of
the U.S.,
Richard TEMBLADOR, a citizen of the U.S., David MERCIER, a citizen of the
U.S., John ARMSTRONG, a citizen of the U.S., and Randy KUMMER, a citizen of
the U.S., applicants for the designation of all countries, and claims priority
to U.S.
Provisional Patent Application Serial No. 60/942,727 filed on 08 June 2007 and
U.S.
Utility Patent Application Serial No. 12/046,488 filed on 12 March 2008.
BACKGROUND
[002] Cable risers are used to supply power, for example, to multi-story
building such as apartments or condominiums. For example, conductors may be
placed in a vertical raceway and run to individual apartments. In some
situations,
due to gravitational forces, conductors within the vertical raceways may slip
down
the annor. For example, to stop this cable slippage, offsets may be used.
Thus, the
conventional strategy is to create horizontal offsets in the vertical raceway
runs to
stop slippage. This often causes problems because conventional systems create
significant costs and time requirements for installing cable risers. In view
of the
foregoing, there is a need for methods and systems for providing vertical
cable and
raceways more optimally. Furthermore, there is a need for providing cable
raceways
with integral (i.e. built-in) support.
SUMMARY
[003] A system for providing cable support may be provided. The system
may comprise a conductor core, a filler that may provide integral core
support, and
armor. The conductor core may comprise at least one conductor. The filler may
be
applied around at least a portion of the conductor core. The armor may be
applied
around at least a portion of the filler. The filler may apply a strong enough
force on
an exterior of the conductor core configured to keep the conductor core from
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=
slipping down an interior of the filler due to a gravitational force. In
addition, the
filler may apply a strong enough force on an interior of the armor configured
to keep
a combination of the conductor core and the filler from slipping down the
interior of
the armor due to the gravitational force.
[003a] According to the present invention, there is provided a cable
comprising:
a conductor core comprising at least one conductor;
a filler around at least a portion of the conductor core,
the filler comprising micro-spheres and a polyethylene, a polyvinyl chloride,
or a nylon; and
an electrically conductive armor around the filler,
the armor comprising a concave side facing the filler, wherein portions of the
filler fill concavities created by the concave side, and the armor is free
of a jacket on an exterior of the armor;
and wherein the cable further comprises a tape separator between the
conductor core and the armor.
[003b] According to the present invention, there is also provided a cable
comprising:
a conductor core comprising two or more conductors;
a tape separator around the conductor core;
a filler around the tape separator,
the filler comprising micro-spheres and a polyethylene, a polyvinyl chloride,
or a nylon; and
an electrically conductive armor around the filler,
the armor comprising a concave side facing the filler, wherein portions of the
filler fill concavities created by the concave side.
[003c] According to the present invention, there is also provided a cable
comprising:
a conductor core comprising at least three conductors and at least one ground
wire;
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a tape separator around the conductor core;
a filler around the tape separator,
the filler comprising a foamed polyvinyl chloride or micro-spheres and a
polyvinyl chloride; and
an electrically conductive armor around the filler,
the armor comprising a concave side facing the filler, wherein portions of the
filler fill concavities created by the concave side.
[003d] According to the present invention, there is also provided a cable
comprising:
a conductor core comprising at least one conductor;
a filler around at least a portion of the conductor core,
the filler comprising a foamed polyethylene, a foamed polyvinyl chloride, or a
foamed nylon; and
an electrically conductive armor around the filler,
the armor comprising a concave side facing the filler, wherein portions of the
filler fill concavities created by the concave side;
and wherein the cable further comprises a tape separator between the
conductor core and the armor.
[004] It is to be understood that both the foregoing general description and
the following detailed description are examples and explanatory only, and
should
not be considered to restrict the invention's scope, as described and claimed.
Further, features and/or variations may be provided in addition to those set
forth
herein. For example, embodiments of the invention may be directed to various
combinations and sub-combinations described in the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[005] The accompanying drawings, which are incorporated in and
constitute a part of this disclosure, illustrate various embodiments of the
present
invention. In the drawings:
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[006] FIG. 1 is a diagram of an armored cable system with integral support;
[007] FIG. 2 is a diagram of an armored cable system with integral support
and tape separator;
[008] FIG. 3 is a diagram of an armored cable system using different fillers
and rubber cord configurations;
[009] FIG. 4 is a diagram of an armored cable system using different fillers
and rubber cord configurations;
[010] FIG. 5 is a diagram of an armored cable system using different fillers
and rubber cord configurations; and
[011] FIG. 6 is a diagram of an armored cable system with grounded armor.
DETAILED DESCRIPTION
[012] The following detailed description refers to the accompanying
drawings. Wherever possible, the same reference numbers are used in the
drawings
and the following description to refer to the same or similar elements. While
embodiments of the invention may be described, modifications, adaptations, and
other implementations are possible. For example, substitutions, additions, or
modifications may be made to the elements illustrated in the drawings, and the
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methods described herein may be modified by substituting, reordering, or
adding
stages to the disclosed methods. Accordingly, the following detailed
description
does not limit the invention.
[013] Consistent with embodiments of the invention, an armored cable with
integral support may be provided. Embodiments of the invention may eliminate
conventional cable offsets in vertical raceway cable installations by
providing
integral support between conductors and the armor. Consequently, the integral
support may keep the conductors within the armor in a vertical raceway
installation
from slipping down due to gravitational forces. Accordingly, embodiments of
the
invention may reduce cable installation time and cost.
[014] FIG. 1 shows a diagram of an armored cable system 100 with integral
support. FIG. 1 shows a cross-section of system 100, which may have a
longitudinal
length. As shown in FIG. 1, system 100 may include a conductor core 105, a
filler
110, and an armor 115. Conductor core 105, though not so limited, may comprise
a
first conductor 120, a second conductor 125, a third conductor 130, a fourth
conductor 135, and a ground wire 140. Fourth conductor 135 may be configured
to
be used as a neutral (e.g. may have an insulation color designating it as a
neutral or
may be of a different size than the other conductors in conductor core 105).
[015] While as shown in FIG.1, conductor core 105 includes four
conductors and a neutral, embodiments of the invention are not so limited. For
example, conductor core 105 may include any number of conductors (e.g.
insulated,
non-insulated, or otherwise) and may include any number of ground wires or may
not include a ground wire. Any one or more of the conductors in conductor core
105
may be configured to be a neutral wire, or none of the conductors in conductor
core
105 may be configured to be a neutral wire. Any one or more of the conductors
or
ground wire(s) in conductor core 105 may have an insulation color indicating
that
any one or more of the conductors or ground wire(s) in conductor core 105 is
intended as a neutral(s). Furthermore, the conductors or ground wire(s) in
conductor
core 105 may all be the same size or they may vary individually or in any sub-
combination by size. In addition, the conductors or ground wire(s) in
conductor core
105 may all be made of the same material (e.g. copper, aluminum, etc.) or they
may
vary individually or in any sub-combination by material. Also, the conductors
or
ground wire(s) in conductor core 105 may all be stranded or solid or they may
vary
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individually or in any sub-combination by being stranded or solid.
Notwithstanding,
conductor core 105 may comprise any conductor construction.
[016] Filler 110 may comprise, but is not limited to, polyethylene,
polyvinyl chloride (PVC), or nylon. A foaming agent, a material comprising
micro-
spheres, or other similar substances may be added to filler 110 before filler
110 is
extruded onto conductor core 105. The foaming agent may be configured to
create
voids in filler 110. When filler 110 is compressed in a first direction (e.g.
toward the
center of system 100,) the voids (or micro-spheres) in filler 110 may tend to
create
an opposing force in filler 110 opposite the first direction. For example,
after being
extruded onto conductor core 105, filler 110 may have a "squeezing" force
applied
to its exterior by armor 115. With this squeezing force applied to filler 110,
the
voids (or micro-spheres) in filler 110 may be configured to cause filler 110
to: i)
apply a strong enough force on the exterior of conductor core 105 to keep
conductor
core 105 from slipping down filler 110's interior due to gravitational forces
on
conductor core 105; and ii) apply a strong enough force on armor 115's
interior to
keep the combination of conductor core 105 and filler 110 from slipping down
armor 115's interior due to the gravitational forces on conductor core 105 and
filler
110. As stated above, micro-spheres added to the filler 110 may cause an
effect
similar to the voids created by the foaming agent. The micro-spheres may tend
to be
more evenly distributed in filler 110 than the voids.
[017] Filler 110 may comprise, but is not limited to, a flexible PVC
compound (e.g. SW1005) with 0.1% to 5% HC-01 foaming agent by weight. The
foaming agent may be supplied by Bayer Corporation of 100 Bayer Road,
Pittsburgh, Pa 15205-9741. Furthermore, as stated above, micro-spheres may be
combined with the flexible PVC compound instead of the foaming agent for
example. The micro-spheres may comprise Expancel micro-spheres 930 MB 120
supplied by Expancel-AKZO NOBEL of 2240 Northmont Parkway, Duluth, GA
30096. The formulation using micro-spheres may comprise 0.5% 930 MB 120 to
99.5% SW1005 by weight. The range of Expancel micro-spheres used may vary,
for example, between 0.1% and 5% by weight.
[018] Notwithstanding, filler 110 may comprise or be augmented with any
substance that (when filler 110 is squeezed) is, for example, capable of: i)
applying a
strong enough force on the exterior of conductor core 105 to keep conductor
core
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105 from sliding down filler 110's interior due to gravitational forces on
conductor
core 105; and ii) applying a strong enough force on the interior of armor 115
to keep
the combination of conductor core 105 and filler 110 from slipping down armor
115's interior due to gravitational forces on conductor core 105 and filler
110.
[019] Armor 115 may comprise any substance (e.g. metallic, non-metallic,
electrically conductive, electrically semi-conductive, etc.) or construction
capable of
creating the aforementioned "squeezing" force applied to filler 110's
exterior. For
example, armor 115 may comprise a continuous strip having a width and being
applied helically around filler 110. The continuous strip, for example, may be
snuggly or tightly wrapped around filler 110. The continuous strip (e.g.
metallic or
non-metallic) may have a concave side facing filler 110. Concavities in the
concave
side may tend to be filled by portions of filler 110 when armor 115 squeezes
filler
110. This concavity filling may aid filler 110 in applying the aforementioned
force
strong enough on the interior of the armor 115 to keep the combination of
conductor
core 105 and filler 110 from slipping down armor 115's interior due to
gravitational
forces on conductor core 105 and filler 110. Armor 115 may be, but is not
limited
to, welded corrugations or other assembly construction such as interlocked
strip or
braided stranding for example.
[020] Consistent with embodiments of the invention, armored cable system
100 may be used in cable risers used to supply power, for example, to multi-
story
building such as apartments or condominiums. For example, armored cable system
100 may be placed in a substantially vertical raceway and run to individual
apartments. Due to gravitational forces, conventional conductors within the
vertical
raceways may slip down the armor. However, consistent with embodiments of the
invention, gravitational forces may not cause conductor core 105 to slip down
armor
115 because armored cable system 100 may include integral support. This may be
true even when armored cable system 100 (and thus conductor core 105) is in a
substantial vertical altitude or position. This integral support may be
created by
filler 110 being "squeezed" by armor 115. With this squeezing force applied to
filler
110, voids or micro-spheres in filler 110 may be configured to cause filler
110 to: i)
apply a strong enough force on the exterior of conductor core 105 to keep
conductor
core 105 from slipping down filler 110's interior due to gravitational forces
on
conductor core 105; and ii) apply a strong enough force on armor 115's
interior to
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keep the combination of conductor core 105 and filler 110 from slipping down
armor 115's interior due to gravitational forces on conductor core 105 and
filler 110.
[021] FIG. 2 shows a diagram of a cable system 200 with integral support
and tape separator. As shown in FIG. 2, system 200 may include the same
elements
of system 100 as described above; however, system 200 may include the addition
of
a tape separator 205. Tape separator 205 may be non-metallic. Notwithstanding
tape separator 205, system 200 may be constructed and may function in ways
similar
to system 100. FIGs. 3 through 5 show other embodiments using different
fillers
and rubber cord configurations.
[022] FIG. 6 shows a diagram of an armored cable system 600 with
grounded armor consistent with embodiments of the invention. System 600 may be
used, for example, in applications where electrical codes may require a
cable's
armor to be well grounded such as in a medical or critical care environment.
As
shown in FIG. 6, system 600 may include a conductor core 605, a filler 610, an
armor 615, and a ground wire 630. FIG. 6 shows a cross-section of system 600,
which may have a longitudinal length. For example, ground wire 630 may be
placed
between filler 610 and armor 615 where ground wire 630 and armor 615 come into
electrical contact at a point 635, for example, as described in more detail
below.
[023] Conductor core 605, though not so limited, may comprise a first
conductor 620 and a second conductor 625. First conductor 620 and second
conductor 625 may respectively include insulation layer 621 and insulation
layer
626. Notwithstanding, conductor core 605 may include more or less conductors
compared to the example shown in FIG. 6. In addition, system 600 may include
more or less ground wires compared to the example shown in FIG. 6. Conductor
core 605 may be of similar construction as conductor code 105 as described
above.
However, conductor core 605 may or may not include a ground wire or neutral
wire.
Similarly, conductor 620 and conductor 625 may be of the same construction as
conductor 120 and conductor 125 respectively as described above and ground
wire
630 may be of the same construction as ground wire 140 as described above.
Moreover, filler 610 and armor 615 may be of similar construction to filler
110 and
armor 115 respectively as described above.
[024] Armor 615 may comprise any substance (e.g. metallic, non-metallic,
electrically conductive, electrically semi-conductive, etc.) or construction
capable of
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creating a "squeezing" force applied to filler 610's exterior. For example,
armor 615
may comprise a continuous strip having a width and being applied helically
around
filler 610. The continuous strip, for example, may be snuggly or tightly
wrapped
around filler 610. The continuous strip may have a concave side facing filler
610.
Concavities in the concave side facing filler 610 may tend to be filled by
portions of
filler 610 when armor 615 squeezes filler 610. As described in more detail
below,
when the aforementioned squeezing force is applied to filler 610 by armor 615,
voids (or micro-spheres) in filler 610 may cause filler 610 to apply a strong
enough
force to ground wire 630 to create an electrical connection between ground
wire 630
and armor 615 at point 635, for example.
[025] As described above with respect to FIG. 6, filler 610 may comprise,
but is not limited to, polyethylene, polyvinyl chloride (PVC), or nylon. A
foaming
agent or a material comprising micro-spheres may be added to filler 610 before
filler
610 is extruded onto conductor core 605. (Examples of the types and amounts of
foaming agent and micro-spheres are described above with respect to filler
110.)
The foaming agent may be configured to create voids in filler 610.
Notwithstanding,
filler 610 may comprise or be augmented with any substance that may be capable
of
causing filler 610 to apply a strong enough force to ground wire 630 to create
an
electrical connection between ground wire 630 and armor 615.
[026] Consistent with embodiments of the invention, when filler 610 is
compressed (e.g. squeezed by armor 615 or otherwise compressed within armor
615)
in a first direction (e.g. toward the center of system 600,) the voids (or
micro-
spheres) in filler 610 may tend to create an opposing force in filler 610
opposite the
first direction. For example, after being extruded onto conductor core 605,
filler 610
may have a squeezing force applied to its exterior by armor 615. With this
squeezing force applied to filler 610 (e.g. toward the center of system 600,)
the voids
(or micro-spheres) in filler 610 may tend to create an opposing force in
filler 610
opposite the first direction. Consequently, this opposing force may cause
filler 610
to apply a strong enough force to ground wire 630 to create an electrical
connection
between ground wire 630 and armor 615. In other words, armor 615 may press
against ground wire 630 on one side of ground wire 630 and filler 610 may
press
against ground wire 630 on a side opposing armor 615. Accordingly, ground wire
630 may snuggly contact armor 615 at at least point 635. Moreover, ground wire
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630 may snuggly contact armor 615 at any number of points along system 600's
longitudinal length and is not limited to contacting armor 615 at only point
635. In
addition, ground wire 630 may contact armor 615 continuously along system
600's
longitudinal length. When ground wire 630 and armor 615 are both electrically
conductive (e.g. both being bare and metallic,) the aforementioned contact
between
ground wire 630 and armor 615 may create an electrical connection between
ground
wire 630 and armor 615.
[027] Consistent with embodiments of the invention, filler 110 or filler 610
may be applied to conductor core 105 or conductor core 605 respectively in any
1 0 manner and there application is not limited to extrusion. Furthermore,
forces caused
by filler 110 or filler 610 are not limited to being created by applying armor
115 or
armor 615 to squeeze filler 110 or filler 610 respectively. These forces
created in
filler 110 or filler 610 may be created in any way. In addition, filler 110
and filler
610 may respectively electrically insulate conductor core 105 and conductor
core
1 5 605 from armor 115 and armor 615. Furthermore, the construction of
system 100 or
system 600 is not limited to any sequence and the elements that make up system
100
or system 600 can be applied in any sequence.
[028] While certain embodiments of the invention have been described,
other embodiments may exist. Further, the disclosed methods' stages may be
20 modified in any manner, including by reordering stages and/or inserting
or deleting
stages, without departing from the invention.
[029] While the specification includes examples, the invention's scope is
indicated by the following claims. Furthermore, while the specification has
been
described in language specific to structural features and/or methodological
acts, the
25 claims are not limited to the features or acts described above. Rather,
the specific
features and acts described above are disclosed as example for embodiments of
the
invention.
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